Wall panel system

ABSTRACT

A wall panel system includes a plurality of wall panels, and one or more hat channels each configured to be attached to a supporting wall and each configured to be attached to the one or more of the plurality of wall panels. The one or more hat channels maintains a predetermined distance between the supporting wall and the plurality of wall panels. One or more keeper members are each configured to be attached to one of the one or more hat channels. When the wall panel system is assembled, each keeper member at least partially supports the weight of the one or more wall panels.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application claims the benefit of U.S. Provisional Patent Application No. 62/992,647, filed Mar. 20, 2020, the entire teachings and disclosure of which are incorporated herein by reference thereto.

FIELD OF THE INVENTION

This invention generally relates to a wall panel system.

BACKGROUND OF THE INVENTION

Exterior, and interior, wall panel systems provide an efficient and cost-effective way to create or improve the appearance of a building. Often used in commercial or industrial building construction, wall panel systems give builders and owners a wide variety of exterior finishes to choose from.

A common problem for many conventional wall panel applications, especially those made from metal, is that, when fixed in some type of channel, the metal panel tend to expand and contract due to normal variations in temperature. Often, this results in a condition known as “oil canning”, which is the buckled or wavy appearance seen in some wall panels.

Embodiments of the present invention address the aforementioned problem and represent an improvement to the state of the art in the construction of both exterior and interior wall panel systems. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.

BRIEF SUMMARY OF THE INVENTION

In one aspect, embodiments of the invention provide wall panel system that includes a plurality of wall panels, and one or more hat channels each configured to be attached to a supporting wall and each configured to be attached to the one or more of the plurality of wall panels. The one or more hat channels maintains a predetermined distance between the supporting wall and the plurality of wall panels. One or more keeper members are each configured to be attached to one of the one or more hat channels. When the wall panel system is assembled, each keeper member at least partially supports the weight of the one or more wall panels

In a particular embodiment, the one or more hat channels are one or more vertical hat channels that extend vertically so as to maintain a horizontal distance between horizontally-adjacent wall panels. In some embodiments, the one or more vertical hat channels maintain a uniform horizontal distance between horizontally-adjacent wall panels.

In other embodiments, the one or more hat channels are one or more horizontal hat channels that extend horizontally so as to maintain a vertical distance between vertically-stacked wall panels. In some embodiments, the one or more horizontal hat channels maintain a uniform vertical distance between vertically-stacked wall panels.

In certain embodiments, the one of the one or more keeper members includes an upper portion and a U-shaped lower portion configured to receive a downward-extending flange from at least one of the plurality of wall panels. At least one of the one or more keeper members may include one or more openings in the U-shaped portion to allow for the escape of moisture. Furthermore, the U-shaped lower portion may be positioned in front of a top flange for one of the plurality of wall panels directly below the at least one of the one or more keeper members.

In a further embodiment, a top-most wall panel includes a hanging flange on a top edge of the top-most wall panel, the hanging flange extending rearward from the top-most wall panel then downward. Embodiments of the invention include a top rail with a U-shaped portion configured to receive the downward-extending portion of the hanging flange. Moreover, the wall panel may be made from aluminum, and the thickness of the aluminum may range from 0.050 of an inch to 0.063 of an inch. At least one of the one or more keeper members and at least one of the one or more hat channels may also be made from aluminum, and the thickness of the aluminum may range from 0.050 of an inch to 0.063 of an inch.

Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:

FIG. 1 is a perspective view of the rear of the wall panel system, constructed in accordance with an embodiment of the invention;

FIG. 2 is a plan view of the wall panel system of FIG. 1, according to an embodiment of the invention;

FIG. 3 is a cross-sectional view of a portion of the wall panel system of FIG. 2;

FIG. 4 is a cross-sectional view of a portion of the wall panel system of FIG. 2 different than that shown in FIG. 3;

FIG. 5 is an enlarged perspective view of a portion of the wall panel system of claim 1;

FIG. 6 is a plan view of the wall panel system with multiple panels, in accordance with an embodiment of the invention;

FIG. 7 is a cross-sectional view of a portion of the wall panel system of FIG. 6;

FIG. 8 is a cross-sectional view of a portion of the wall panel system of FIG. 6 different than that shown in FIG. 7;

FIG. 9 is a perspective view of a keeper member used in the rear of the wall panel system, in accordance with an embodiment of the invention;

FIG. 10 is a plan view of a horizontal panel wall system, in accordance with an embodiment of the invention;

FIG. 11 is a cross-sectional view of a portion of the wall panel system of FIG. 10;

FIG. 12 is a plan view of a vertical panel wall system, in accordance with an embodiment of the invention;

FIG. 13 is a cross-sectional view of a portion of the wall panel system of FIG. 12;

FIG. 14 is a cross-sectional view of a portion of the wall panel system of FIG. 12 different than that shown in FIG. 13.

While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention described herein include a wall panel system that could be used on the interior or exterior of commercial and industrial buildings. As will be shown below, embodiments of the invention show a wall panel system composed of stackable horizontal wall panels, and a wall panel system composed of stackable vertical wall panels. In both systems, the wall panels are tied together using devices referred to below as keeper members, and hat channels. The hat channels may be horizontal or vertical and the wall panels and keeper members may be mounted onto the various hat channels.

FIG. 1 is a perspective view of the rear of a wall panel system 100, constructed in accordance with an embodiment of the invention. FIG. 2 is a plan view of the same wall panel system 100. The wall panel system 100 is made from a plurality of wall panels 102 assembled side-by-side and, in some cases, stacked vertically as well. To address the oil canning problem associated with conventional wall panels, embodiments of the present invention provide for a “free-floating panel” within the confines of the keeper channels, such that the wall panel 102 is allowed to expand and contract uninhibited in the wall panel system 100 disclosed herein.

The wall panels 102 may be made from a variety of suitable materials. In specific embodiments of the invention, the wall panels 102 are made from aluminum. In a particular embodiment of the invention, aluminum panels 102 are constructed using aluminum of either 0.050″ or 0.063″ thickness. However, it is understood that the wall panels 102 and channel members may both be made of aluminum, or some other similarly suitable material, whose thickness is less than 0.050″ or greater than 0.063″.

FIG. 3 is a cross-sectional view of a portion of the wall panel system 100 of FIG. 2, while FIG. 4 is a cross-sectional view of a portion of the wall panel system 100 of FIG. 2 different than that shown in FIG. 3. FIG. 3 shows an embodiment of a top-most wall panel 102 which includes a hanging flange 104. The hanging flange 104 is designed to fit over a top rail 120 (shown in FIG. 13) which supports the top-most wall panel 102. FIG. 4 is a schematic cross-sectional view of two vertically-stacked wall panels 102 which is illustrated in FIG. 8 and described in more detail below.

In specific embodiments and as shown in FIG. 3, the top-most wall panel 102 includes a hanging flange 104 that extends out rearward and horizontally from a top edge of the top-most wall panel 102 toward the supporting wall, and then downward. The downward-extending portion of the hanging flange 104 is inserted into the U-shaped portion of a top rail 120 (shown in FIG. 13).

FIG. 5 is an enlarged perspective view of a rear portion of the wall panel system 100 of claim 1. In this embodiment, a first wall panel 102 has a side flange 106 with a notch toward a lower end thereof is shown. The side flange 106 abuts a top flange 110 of a second wall panel 102 directly below the first wall panel 102.

FIG. 6 is a plan view of the wall panel system 100 with multiple wall panels 102, in accordance with an embodiment of the invention, while FIGS. 7 and 8 show two different cross-sections of the wall panel system 100 of FIG. 6. In the embodiment shown, the wall panel system 100 includes a sill 112 that runs along the floor below the wall panels 102. A vertical reveal 114 runs vertically from the sill 112 to the top of the wall panel system 100.

In the embodiment shown, the wall panel system 100 is supported by the sill 112 at the base of the wall. The sill 112 may also support one or vertical reveals 114, attached to the sill 112 at the floor level. The sill 112 may also include one or more horizontal support channels to support and separate the bottom-most wall panels 102 from the floor. As shown in FIG. 6, a vertical reveal 114 provides horizontal separation between adjacent wall panels 102. FIG. 7 shows the vertical reveal 114 between adjacent wall panels 102, where the vertical reveal 114 is attached to the wall using a fastener 118, such as a nail or screw.

A horizontal reveal 116 runs horizontally (e.g., between vertical reveals 114), and provides vertical separation between vertically-stacked wall panels 102. As shown in FIG. 8, the horizontal reveal 116 may be a keeper member 124 of the type illustrated. In certain embodiments, the vertically-stacked wall panels 102 are separated by horizontal reveals 116, which may be strips of metal, or some other suitable material, that define the horizontal channels between vertically-stacked wall panels 102. Similarly, the aforementioned vertical reveals 114 may also be strips of metal, or some other suitable material, that defines the vertical channels between horizontally-aligned wall panels 102. In alternate embodiments of the invention, the wall panels 102 are stacked directly on top of each other and/or side-by-side in a free-floating manner so that no vertical or horizontal reveal 114, 116 is needed.

FIG. 9 is a perspective view of the keeper member 124 typically located at the rear of the wall panel system 100, in accordance with an embodiment of the invention. As can be seen in FIG. 9, embodiments of the keeper member 124 may include one or more openings 125 at a bottom-most portion of the keeper member 124 to allow moisture to escape. In particular embodiments, the keeper member 124 includes an upper panel 126 which may be attached to the wall using the same type of fastener 118 described above. Blow the upper panel 126, a channel portion 128 is configured to receive and support a lower flange 130 of the wall panel 102. The one or more openings 125 may be at the bottom of the channel portion 128.

In this way, the keeper member 124 positioned below the wall panel 102 supports the weight of the wall panel 102. With respect to the keeper member 124 positioned above the wall panel 102, the top flange 110 of the wall panel 102 extends upward behind the channel portion 128 of the keeper member 124 positioned above to keep the wall panel upright and against the wall.

In particular embodiments, the upper panel 126 of the keeper member 124 may include long relatively straight portion which can be attached to a hat channel member described in more detail below. The channel portion 128 of the keeper member 124 may be substantially U-shaped and extend downward from the upper panel 126. The U-shaped channel portion 128 is designed to securely hold the downward-extending lower flange 130 of the wall panel 102 such that the wall panel is not prohibited from expanding or contracting due to temperature variation, but is nevertheless securely held in place. Further, the keeper member 124 helps maintain a uniform vertical spacing between vertically-stacked wall panels 102. However, alternate embodiments allow for keeper members 124 designed to maintain varying or non-uniform spacing between wall panels 102.

One of the advantages of the wall panel system 100 described herein is the wall panel's ability to “free-float” within the keeper channels 124. Because embodiments of the present invention provide for a “free-floating panel” within the confines of the keeper channels 124, the wall panel system is not susceptible to oil canning, as the system 100 is not significantly affected by the expansions and contractions of individual wall panels 102 due to normal temperature variation.

FIG. 10 shows a particular embodiment of a wall panel system 131 in which the wall panels 132 extend further in the horizontal direction than in the vertical direction. FIG. 11 shows a cross-section of wall panel system 131 with two stacked wall panels 132 and the keeper member 124 positioned between the two wall panels 132. As can be seen in FIG. 11, the wall panels 132 and keeper members 124 are attached to a vertical hat channel 134 that extends from the floor to the top of the wall panel system 131. The vertical hat channel 134 is attached to the wall and provides a point of attachment for the wall panels 132 and keeper members 124.

FIG. 12 shows a particular embodiment of a wall panel system 141 in which the wall panels 142 extend further in the vertical direction than in the horizontal direction. FIGS. 13 and 14 show two different cross-sections of wall panel system 141 with two stacked wall panels 142 and the keeper member 124 positioned between the two wall panels 132. As can be seen in FIGS. 13 and 14, the wall panels 142 and keeper members 124 are attached to a horizontal hat channel 144 that extends horizontally across adjacent wall panels 142 of the wall panel system 131. The horizontal hat channel 144 is attached to the wall and provides a point of attachment for the wall panels 142 and keeper members 124. FIG. 13 also shows the top rail 120 designed to receive the hanging flange 104 of the top-most wall panel 102.

The top rail 120 is similar to the aforementioned keeper members 124, but typically, though not necessarily, has a different shape. In a particular embodiment, the top rail 120 has a straight portion for attachment to the supporting wall, and an angled portion which connects that straight portion to the U-shaped portion that helps support the weight of the top-most wall panel 102.

Like the wall panels 102, in particular embodiments, the vertical and horizontal hat channel members 134, 144 are constructed of aluminum of either 0.050″ or 0.063″ thickness, or some thickness in between. The wall panel system 100 with the above-described vertical reveals 114 and the vertical and horizontal hat channels 134, 144 in combination with the keeper members 124, allows for the wall panels 102 to be easily and quickly assembled one upon another, and side-by-side. This allows for a much faster, and less expensive, installation process.

The wall panels 102 are vertically stackable and spaced horizontally through the use of the aforementioned vertical and horizontal hat channels 134, 144 which attach to the supporting wall and maintain uniform separation between adjacent wall panels 102 and between the wall panels 102 and the supporting wall. It is also envisioned that, in some embodiments, the vertical and horizontal hat channels 134, 144 may be designed to maintain a varying, or non-uniform, separation between the wall panels and the supporting wall.

Vertical hat channels 134 are typically used in wall panel systems 131 comprised of horizontal wall panels 132, while horizontal hat channels 144 are typically used in wall panel systems 141 comprised of vertical wall panels 142. In both types of wall channels, vertical stacking is facilitated by the use of the aforementioned keeper members 124 which are attached to the vertical and horizontal hat channels 134, 144.

Certain embodiments of the wall panel system may be used in conjunction with a rain screen type system. A rain screen system is not by design a waterproof system, rather it is water-inhibiting system which relies on a waterproof substrate for water-tight integrity.

All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. 

What is claimed is:
 1. A wall panel system comprising: a plurality of wall panels; one or more hat channels each configured to be attached to a supporting wall and each configured to be attached to the one or more of the plurality of wall panels, the one or more hat channels maintaining a predetermined distance between the supporting wall and the plurality of wall panels; and one or more keeper members each configured to be attached to one of the one or more hat channels, wherein, when the wall panel system is assembled, each keeper member at least partially supports the weight of the one or more wall panels.
 2. The wall panel system of claim 1, wherein the one or more hat channels are one or more vertical hat channels that extend vertically so as to maintain a horizontal distance between horizontally-adjacent wall panels.
 3. The wall panel system of claim 2, wherein the one or more vertical hat channels maintain a uniform horizontal distance between horizontally-adjacent wall panels.
 4. The wall panel system of claim 1, wherein the one or more hat channels are one or more horizontal hat channels that extend horizontally so as to maintain a vertical distance between vertically-stacked wall panels.
 5. The wall panel system of claim 4, wherein the one or more horizontal hat channels maintain a uniform vertical distance between vertically-stacked wall panels.
 6. The wall panel system of claim 1, wherein the one of the one or more keeper members includes an upper portion and a U-shaped lower portion configured to receive a downward-extending flange from at least one of the plurality of wall panels.
 7. The wall panel system of claim 6, wherein at least one of the one or more keeper members includes one or more openings in the U-shaped portion to allow for the escape of moisture.
 8. The wall panel system of claim 6, wherein the U-shaped lower portion is positioned in front of a top flange for one of the plurality of wall panels directly below the at least one of the one or more keeper members.
 9. The wall panel system of claim 1, wherein a top-most wall panel includes a hanging flange on a top edge of the top-most wall panel, the hanging flange extending rearward from the top-most wall panel then downward.
 10. The wall panel system of claim 9, further comprising a top rail with a U-shaped portion configured to receive the downward-extending portion of the hanging flange.
 11. The wall panel system of claim 1, wherein the wall panel is made from aluminum.
 12. The wall panel system of claim 10, wherein a thickness of the aluminum ranges from 0.050 of an inch to 0.063 of an inch.
 13. The wall panel system of claim 1, wherein at least one of the one or more keeper members and at least one of the one or more hat channels is made from aluminum.
 14. The wall panel system of claim 12, wherein a thickness of the aluminum ranges from 0.050 of an inch to 0.063 of an inch. 